NHTSA ID Number: 11027759
Manufacturer Communication Number: B160225
TSB/Document Date: 2026-01-23
Summary
The assembly cover on the left side of the fuel tank may not have been properly plastic welded. Thiscould lead to a smell of fuel after refueling or service engine soon light (MIL) for an evaporative leakin the fuel system.
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TSB/Document ID: B160225
Replacement Service Bulletin Number:
MFR Communication Date: 2026-01-17
MFR Internal Campaign ID/Software Version: 0016940200
Communication Type: Service Campaign
NHTSA Components: FUEL/PROPULSION SYSTEM
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
1/21/26, 3:35 PM
16 02 25_SERVICE ACTION: REPLACE THE FUEL TANK
SIB 16 02 25
SERVICE ACTION: REPLACE THE FUEL TANK
2026-01-16
Please perform the procedure outlined in this Service Information on all affected vehicles before
customer delivery. In the event the customer has already taken delivery of the vehicle, please perform
the procedure the next time the vehicle is in the shop if the campaigns have a status of remedy
available. Otherwise, please release the vehicle.
☐
THIS REPAIR IS MOBILE FRIENDLY
☐
THIS REPAIR IS REMOTE SOFTWARE UPGRADE (RSU) FRIENDLY
MODEL
E-Series
Model Description
Production Date
G60
5 Series Sedan
October 18, 2023 – February 8, 2024[AM1]
AFFECTED VEHICLES
Vehicles which require this campaign to be completed will show it as “Open” when checked either in AIR,
AWP, Campaign Summary, or Warranty Vehicle Inquiry
Please make sure you check your dealer inventory as soon as possible. You can see a list of affected
vehicles in Inventory Campaign Details (ICD) under ROSS.
SITUATION
The assembly cover on the left side of the fuel tank may not have been properly plastic welded. This
could lead to a smell of fuel after refueling or service engine soon light (MIL) for an evaporative leak
in the fuel system.
CORRECTION
Replace the fuel tank.
PROCEDURE
Replace the fuel tank following in Repair Instructions REP 16 11 031 Removing and installing/replacing
the fuel tank.
PARTS INFORMATION
Use and invoice the applicable part numbers below.
Part Number
Description
Quantity
16 11 5 A27 D49
Fuel tank repair kit
1
07 12 9 952 117
2
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16 02 25_SERVICE ACTION: REPLACE THE FUEL TANK
51 71 5 A11 DD1
Sealing cap, floor panel, rear
1
16 11 7 188 567
1
07 11 9 906 672
Hexagon bolt
4
33 12 7 607 158
Recessed nut repair kit, blue
1
26 11 7 523 708
Hexagon bolt
3
26 12 7 536 563
Self-locking hexagon nut
3
18 30 5 A22 701
Clamp
07 14 5 A67 B87
Hexagon nut
1[AM2]
3
Additionally, other materials and small parts that are not specified above, such as fluids, lubricants (in
sublet), one-time use screws, nuts, and seals, which must be replaced or installed (according to the ISTA
repair instructions/ETK/AIR), are to be selected from the Electronic Parts Catalog, and/or other approved
BMW Group’s resources according to the respective vehicle type. Invoiced these items separately under the
Repair Code listed in this bulletin.
CLAIM INFORMATION
Reimbursement for this Action will be via normal claim entry utilizing the applicable work package
information below, and the part number listed above.
Repair
Code:
0016940200
G60 B48 B58 Replacing fuel tank
Below are the special flat rate labor operation code choices for this action.
The vehicle is already in the workshop for another reason and/or repair.
Work Package
Labor
Operation
Description (Plusposition)
Labor Allowance
#1
00 79 582
Replace the fuel tank with
suctioning and returning the fuel
40 FRU (540i
xDrive);
42 FRU (530i All)
Or:
The vehicle arrives at your center, and this Service Action shows open (No other Main work will be
performed or claimed during this workshop visit).
Work Package
about:blank
Labor
Operation
Description (Main work)
Labor Allowance
Copyright ©2026 BMW of North America, Inc.
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#2
16 02 25_SERVICE ACTION: REPLACE THE FUEL TANK
00 79 065
Replace the fuel tank with
suctioning and returning the fuel
41 FRU (540i
xDrive);
44 FRU (530i All)
Only one of the flat rate labor operation codes listed above can be used for claim submission and
reimbursement. Also, only one Main work flat rate labor operation code can be claimed per workshop
visit.
Claim Repair Comments
Reference the SIB number, the issue (briefly), and the work package (WP) number performed in the
technician’s RO notes, and in the claim comments (For example: B16 02 25 Replace fuel tank WP 1),
unless otherwise required by State law.
Alternative Mobility Solution (AMS) for Vehicle Owners (RO and Claim Comments Required)
This Service Action repair qualifies for Alternative Mobility Solution (AMS) expense reimbursement, claim
this item under the Defect Code noted above as follows:
Sublet Code 2 - Itemize the AMS sublet amount on the repair order and in the claim comment
section.
Please refer to SI B01 29 16 for additional information.
FEEDBACK REGARDING THIS BULLETIN
Technical Feedback
To submit feedback for the technical topic of this bulletin: Submit your
feedback in the rating box at the top of this bulletin
Warranty Feedback
To submit feedback for the CLAIMS section of this bulletin: Submit an
IDS ticket to the Warranty Department, or use the chat available in the
Warranty Documentation Portal
Parts Feedback
To submit feedback for the PARTS section of this bulletin: Submit an
IDS ticket to the Parts Department
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16 02 25_SERVICE ACTION: REPLACE THE FUEL TANK
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